Description
Doosan QSL9 Cummins Shop Manual (QSL9CumminsEng)
Doosan QSL9 Cummins Index:
QSL9 Cummins Engine
Safety Precautions………………………………………… 7
Applicable Models…………………………………………. 7
QSL9 Engine ……………………………………………….. 8
Important Reference Numbers …………………………………. 9
Introduction………………………………………………… 10
To the Owner and Operator ……………………………………. 10
About the Manual …………………………………………………. 10
How to Use the Manual …………………………………………. 11
Illustrations ………………………………………………………….. 11
General Safety Instructions ……………………………………. 12
General Repair Instructions……………………………………. 15
General Cleaning Instructions ………………………………… 17
Acronyms and Abbreviations………………………………….. 24
Engine Identification ……………………………………. 25
Engine Data Plate ………………………………………………… 25
Cummins Engine Nomenclature……………………………… 26
Fuel Injection Pump Data Plate………………………………. 26
ECM Data Plate……………………………………………………. 27
Engine Diagrams………………………………………………….. 28
Engine Specification……………………………………………… 33
Operating Instructions …………………………………. 35
Operating Instructions – Overview…………………………… 35
Normal Starting Procedure…………………………………….. 36
Cold Weather Starting …………………………………………… 37
Starting Procedure After Extended Shutdown or Oil
Change……………………………………………………………….. 37
Operating the Engine ……………………………………………. 38
Engine Operating Range……………………………………….. 40
Engine Shutdown …………………………………………………. 40
Electronic Controlled Fuel System………………………….. 41
Appendix. SAE Diagnostic Trouble Codes and Cummins
Fault Codes …………………………………………………………. 50
Maintenance Guidelines ………………………………. 62
Maintenance Guidelines – Overview………………………… 62
Tool Requirements ……………………………………………….. 62
Maintenance Schedule………………………………………….. 63
Maintenance Procedures at Daily Interval ………. 65
Daily Maintenance Procedures – Overview ………………. 65
Air Intake Piping …………………………………………………… 66
Fan, Cooling ………………………………………………………… 66
Crankcase Breather Tube………………………………………. 67
Coolant Level……………………………………………………….. 68
Fuel-Water Separator ……………………………………………. 69
Lubricating Oil Level ……………………………………………… 69
Maintenance Procedures at 250 Hours or 3
Months………………………………………………………. 70
Maintenance Procedures – Overview ………………………. 70
Air Cleaner Restriction ………………………………………….. 70
Charge-Air Cooler ………………………………………………… 71
Charge-Air Piping …………………………………………………. 71
Fuel Pump…………………………………………………………… 72
Maintenance Procedures at 500 Hours or 6
Months………………………………………………………. 73
Maintenance Procedures – Overview ………………………. 73
Fuel Filter (Spin-On Type) ……………………………………… 73
Lubricating Oil and Filters………………………………………. 75
Supplemental Coolant Additive (SCA) and Antifreeze
Concentration ………………………………………………………. 78
Coolant Filter ……………………………………………………….. 79
Batteries ……………………………………………………………… 81
Battery Cables and Connections…………………………….. 82
Maintenance Procedures at 1,000 Hours or 1 Year
84
Maintenance Procedures – Overview ………………………. 84
Drive Belts …………………………………………………………… 84
Fan Hub, Belt Driven …………………………………………….. 85
Drive Belt, Cooling Fan………………………………………….. 85
Turbocharger ……………………………………………………….. 86
Maintenance Procedures at 2,000 Hours or 2
Years…………………………………………………………. 87
Maintenance Procedures – Overview ………………………. 87
Cooling System ……………………………………………………. 87
Vibration Damper, Rubber……………………………………… 91
Engine Steam Cleaning…………………………………………. 92
Radiator Hoses…………………………………………………….. 92
Engine Mounting Bolts ………………………………………….. 93
Maintenance Procedures at 5000 Hours or 4 Years
94
Overhead Set ………………………………………………………. 94
Adjustment, Repair and Replacement ……………. 97
Engine Storage – Long Term ………………………………….. 97
Lubricating Oil Dipstick………………………………………….. 97
Drive Belt, Cooling Fan………………………………………….. 98
Belt Tensioner, Automatic (Water Pump)………………….. 99
Drive Belt, Alternator …………………………………………… 100
Alternator…………………………………………………………… 100
Charge-Air Cooler ………………………………………………. 102
Starting Motor…………………………………………………….. 105
System Diagrams ……………………………………… 107
System Diagrams – Overview……………………………….. 107
Fuel System ………………………………………………………. 108
Lubricating Oil System ………………………………………… 110
Cooling System ………………………………………………….. 114
Air Intake System ……………………………………………….. 116
Service Literature ……………………………………… 118
Additional Service Literature ………………………………… 118
Service Literature Ordering Location……………………… 118
Cummins Customized Parts Catalog …………………….. 119
Troubleshooting Symptoms ………………………… 121
Troubleshooting Procedures and Techniques………….. 121
Troubleshooting Symptoms Charts ……………………….. 121
Maintenance Specifications………………………… 162
General Engine ………………………………………………….. 162
Fuel System ………………………………………………………. 162
Lubricating Oil System ………………………………………… 163
Cooling System ………………………………………………….. 163
Air Intake System ……………………………………………….. 164
Exhaust System …………………………………………………. 164
Electrical System………………………………………………… 164
Cummins/Fleetguard Filter Specifications………………. 165
Fuel Recommendations and Specifications ……………. 165
Lubricating Oil Recommendations and Specifications 167
Drive Belt Tension ………………………………………………. 170
Engine Component Torque Values………………………… 171
Sealants ……………………………………………………………. 171
Cap Screw Markings and Torque Values………………… 172
Warranty ………………………………………………….. 175
All Engines United States and Canada Industrial (Off-
Highway)……………………………………………………………. 175
All Engines International Industrial (Off-Highway) ……. 179
California Emission Control System Warranty, Off-
Highway…………………………………………………………….. 182
Component Manufacturers …………………………. 186
Service Assistance ……………………………………. 190
Routine Service and Parts……………………………………. 190
Emergency and Technical Service ………………………… 190
Problem Solving …………………………………………………. 190
Division and Regional Offices – Locations………………. 192
Distributors and Branches – United States ……………… 193
Distributors and Branches – Canada ……………………… 208
Distributors and Branches – Australia …………………….. 211
Distributors and Branches – New Zealand………………. 214
Regional Offices – International – Locations ……………. 215
Distributors – International – Locations……………………. 222
